Toilet scrubber and toilet cleaner

ABSTRACT

Disclosed is a toilet scrubber which comprises a non-woven cleaning fabric layer comprising a cleaning composition, and a functional non-woven fabric layer comprising a functional composition, and a toilet cleaner having the toilet scrubber.

FIELD

The present disclosure relates to a toilet scrubber and a toilet cleaner.

BACKGROUND OF THE INVENTION

Toilet scrubbers have been widely used to remove contaminants on the toilet surface. For example, as shown in FIG. 1, a toilet scrubber 1 consists of only one layer for removing contaminants. The toilet scrubber 1 is used while one side thereof is connected to a handle 2. As described above, the toilet scrubber of the prior art has only a function of removing contaminants, but does not have other functions, such as protecting the toilet surface from the contaminants after cleaning or removing bad smells, which causes an inconvenience in that the toilet needs to be frequently cleaned.

SUMMARY OF THE INVENTION

The disclosed toilet scrubber has superior ability to remove contaminants on the toilet surface as well as imparting antibiotic, anti-contaminating, and deodorizing effects to the toilet surface. In one embodiment, a toilet scrubber comprises a non-woven cleaning fabric layer including a cleaning composition and a functional non-woven fabric layer including a functional composition. In one embodiment, a toilet cleaner comprises the toilet scrubber and a handle connected to one side of the toilet scrubber.

In one embodiment, there is provided a method of preparing a toilet scrubber including the steps of forming a first non-woven fabric by using a first polyester-based staple fiber, a first polyamide-based staple fiber, or a mixture thereof; coating a cleaning composition on the first non-woven fabric to form a non-woven cleaning fabric layer; forming a second non-woven fabric by using a second polyester-based staple fiber, a second polyamide-based staple fiber, or a mixture thereof; coating a functional composition on the second non-woven fabric to form a functional non-woven fabric layer; laminating the non-woven cleaning fabric layer on the functional non-woven fabric layer to form a laminate sheet; and cutting the laminate sheet.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view showing a toilet scrubber of the prior art;

FIG. 2 is a perspective view showing a toilet scrubber according to an exemplary embodiment of the present invention;

FIG. 3 is a perspective view showing a toilet cleaner according to an exemplary embodiment of the present invention;

FIG. 4 is a graph showing whiteness of tile surfaces after the tile surfaces are coated with steak sauce and then respectively cleaned by toilet scrubbers of Examples 1 to 3 and Comparative Example 1;

FIG. 5 is a graph showing whiteness of tile surfaces after the tile surfaces are coated with rice paste and then respectively cleaned by the toilet scrubbers of Examples 1 to 3 and Comparative Example 1;

FIG. 6 is a graph showing contaminant removal on tile surfaces after the tile surfaces are respectively coated with steak sauce and rice paste and then respectively cleaned by the toilet scrubbers of Examples 1 to 3 and Comparative Example 1;

FIG. 7 is a graph showing anti-contaminating efficiency of the toilet scrubbers of Examples 1 to 3 and Comparative Example 1; and

FIG. 8 shows images displaying propagation or non-propagation of staphylococcus 5 minutes after Staphylococcus ATCC 6538 is inoculated on tiles respectively cleaned by the toilet scrubbers of Examples 1 to 3 and Comparative Example 1; and images displaying propagation or non-propagation of E. coli 5 minutes after Escherichia Coli ATCC 25922 is inoculated on tiles respectively cleaned by the toilet scrubbers of Examples 1 to 3 and Comparative Example 1.

DETAILED DESCRIPTION

The disclosed toilet scrubber can effectively remove germs and bad smells as well as contaminants on the toilet surface, protect the toilet surface from the contaminants, and suppress the propagation of germs on the toilet surface, by including a non-woven cleaning fabric layer including a cleaning composition and a functional non-woven fabric layer including a functional composition.

FIG. 2 is a perspective view of a toilet scrubber 100. The toilet scrubber 100 includes a non-woven cleaning fabric layer 10 and a functional non-woven fabric layer 20.

The non-woven cleaning fabric layer 10, which removes contaminants on the toilet surface, includes a first non-woven fabric and a cleaning composition formed on a surface of the first non-woven fabric and/or inside the first non-woven fabric.

The first non-woven fabric includes a first polyester-based staple fiber, a first polyamide-based staple fiber, or a mixture thereof. Specifically, as for the first non-woven fabric, the first polyester-based staple fiber(s) and/or the first polyamide-based staple fiber(s) are both physically interlaced with and bonded to each other by various non-woven fabric preparing methods known in the art. This first non-woven fabric can extend the lifespan of the toilet scrubber due to excellent durability thereof. In order to prepare the non-woven fabric, there are methods of thermally, physically or chemically bonding webs each consisting of fibers to each other, such as, bonding the fibers in the webs to each other by using an adhesive or melting the fibers in the web to bond the fibers with each other. Examples thereof are thermal bonding, spun-bond, and the like, but are not limited thereto.

The first polyester-based staple fiber is a synthetic fiber obtained by spinning a polymer containing an ester (—COO—) bond on a main chain and then slitting it into a predetermined length. The first polyester-based staple fiber has superior durability and flexibility, resulting in fewer scratches on the toilet at the time of using the final scrubber. Further, the first polyester-based staple fiber has excellent acid resistance, alkali resistance, and chemical resistance; high mechanical strength; little change in strength even when the scrubber is wet; is hardly discolored; and has low absorptiveness to water and thus very high dryness. Therefore, the first non-woven fabric including the first polyester-based staple fiber has high dryness and strength, excellent durability, strength, wear resistance, and chemical resistance, and the like, so that the durability, strength, and wear resistance of the toilet scrubber can be also improved.

Non-limited examples of the first polyester-based staple fiber are a polyethylene terephthalate staple fiber, a polyethylene naphthalate staple fiber, a polybutylene terephthalate staple fiber, a poly(1,4-cyclohexylenedimethylene terephthalate staple fiber, a polyesterether staple fiber, a polyetheretherketone staple fiber, and the like, which may be used alone or in a mixture of two or more thereof.

The fineness of the first polyester-based staple fiber is not particularly limited. But when the first polyester-based staple fiber used is too thin, a large amount of fibers are needed for giving volume, which causes the non-woven fabric layer to be too dense and stiffened and the preparation cost to be increased. In the case where the fineness of the first polyester-based staple fiber is controlled to be about 20 to 80 denier and desirably about 40 to 60 denier, a final toilet scrubber having sufficient volume and excellent touch can be prepared at a low cost.

The first polyamide-based staple fiber is a synthetic fiber obtained by spinning a polymer containing an amide (—CONH—) bond on a main chain and then slitting it into a predetermined length. The first polyamide-based staple fiber has superior durability and flexibility, resulting in fewer scratches on the toilet at the time of using the final scrubber. Further, the first polyamide-based staple fiber has low absorptiveness to water and thus very high dryness; high strength; and excellent elasticity, wear resistance, chemical resistance, and heat resistance. Therefore, the first non-woven fabric including the first polyamide-based staple fiber has high dryness and strength and excellent durability, strength, wear resistance, chemical resistance, and heat resistance, so that the durability, strength, and wear resistance of the toilet scrubber can be also improved.

Examples of the first polyamide-based staple fiber are nylon 6, nylon 66, nylon 11, nylon 610, nylon 612, nylon 4, aromatic nylon, aramid, and the like, but are not limited thereto.

The fineness of the first polyamide-based staple fiber is not particularly limited. However, when the fineness of the first polyamide-based staple fiber is controlled to be about 20 to 80 denier and desirably about 40 to 60 denier, like the first polyester-based staple fiber, it can increase volume and improve touch of the final toilet scrubber and result in a reduction in the preparation cost thereof.

The use of the polyamide-based staple fiber as described above leads to an improvement in durability and touch feeling but an increase in the preparation cost thereof, as compared with the use of the polyester-based staple fiber.

The non-woven cleaning fabric layer 10 includes a cleaning composition. The cleaning composition may coat a surface of the first non-woven fabric or fill an inside of the first non-woven fabric, or may both coat a surface of the first non-woven fabric and fill an inside of the first non-woven fabric. The cleaning composition may be eluted at the time of using the toilet scrubber to thereby remove contaminants on the toilet surface.

According to one embodiment, the cleaning composition may include an anionic surfactant; an ethanolamine-based compound; a pigment and/or dye; and a solvent.

Examples of the anionic surfactant used herein are sodium decylbenzene sulfonate, sodium dodecylbenzene sulfonate, ammonium methyl dodecylbenzene sulfonate, ammonium dodecylbenzene sulfonate, sodium octadecylbenzene sulfonate, sodium nonylbenzene sulfonate, sodium dodecylnaphthalene sulfonate, sodium heptadecylbenzene sulfonate, potassium eicososyl naphthalene sulfonate, ethylamine undecylnaphthalene sulfonate, sodium docosylnaphthalene sulfonate, sodium octadecyl sulfate, sodium hexadecyl sulfate, sodium dodecyl sulfate, sodium nonyl sulfate, ammonium decyl sulfate, potassium tetradecyl sulfate, diethanolamino octyl sulfate, triethanolamine octadecyl sulfate, ammonium nonyl sulfate, ammonium nonylphenoxyl tetraethylenoxy sulfate, sodium dodecylphenoxy triethyleneoxy sulfate, ethanolamine decylphenoxy tetraethyleneoxy sulfate, potassium octylphenoxy triethyleneoxy sulfate, and the like, but are not limited thereto. They may be used alone or in a mixture of two or more thereof. For example, a mixed material of dodecylbenzene sulfonate neutralized with Na and dodecylbenzene sulfuonate neutralized with triethanol amine may be used.

The amount of the anionic surfactant is not particularly limited. However, when the amount of anionic surfactant used is too small, a desired cleaning power may not be obtained. On the contrary, when the amount of anionic surfactant used is too large, the preparation cost may be increased, and viscosity of the cleaning composition is too high, which makes it difficult to coat on the first non-woven fabric by a roll coating method or the like. Hence, the amount of anionic surfactant may be controlled to be about 40 to 60 wt % based on the total weight of the cleaning composition. For example, 25 to 40 wt % of dodecylbenzene sulfonate neutralized with Na and 15 to 20 wt % of dodecylbenzene sulfuonate neutralized with triethanol amine may be used.

The ethanolamine-based compound used herein has a good mixablity with water and high viscosity, thereby preventing an anionic surfactant or a pigment and/or dye from being separated at the time of forming a non-woven cleaning fabric layer. Further, it allows components in the cleaning composition to be homogeneously dispersed, thereby reducing the generation of flakes in a slitting process at the time of preparing the scrubber, and further improving the cleaning effect together with the anionic surfactant.

Examples of the ethanolamine-based compound are diethanolamine, triethanolamine, and the like, but are not limited thereto.

The amount of the ethanolamine-based compound is not particularly limited. However, when the amount of the ethanolamine-based compound is about 15 to 20 wt % based on the total weight of the cleaning composition, it can reduce the generation of flakes in a slitting process at the time of preparing the scrubber and further improve the cleaning effect together with the anionic surfactant.

The pigment and/or dye used herein are/is not particularly limited as long as it can be eluted together with other components when being contacted with water. Non-limited examples of the pigment or dye are pigments such as Nylosan Blue, Hostafine Blue, AquaLor Blue, water-soluble dyes such as Direct Blue 76, Direct Blue 86, Direct Blue 108, Direct Blue 199, Direct Blue 236, Acid Blue 9, Acid Blue 78, Acid Blue 82, and Acid Blue 234, and the like. Due to the inclusion of the pigment and/or dye, the color of the toilet scrubber becomes lighter as the toilet scrubber is more often used, so that the replacement time of the toilet scrubber can be anticipated.

The amount of the pigment, dye, or mixture thereof is not particularly limited, but may be controlled to be 0.05 to 10 wt % based on the total weight of the cleaning composition depending on the coloring degree of the non-woven cleaning fabric layer.

The solvent used herein is not particularly limited as long as it can easily dissolve the anionic surfactant, the ethanolamine-based compound, and the pigment and/or dye. Examples of the solvent are water and the like.

The amount of the solvent is not particularly limited, but may be a remainder that controls the total weight of the cleaning composition to be 100 wt %.

The viscosity of the cleaning composition is not particularly limited. However, when the viscosity of the cleaning composition is 200 to 600 cps, it can easily coat a surface of the first non-woven fabric as well as fill the inside of the first non-woven fabric by a roll coating method or the like.

In addition, the coating amount (use amount) of the cleaning composition is not particularly limited. However, when the coating amount of the cleaning composition is 20 to 40 parts by weight based on 100 parts by weight of the first non-woven fabric, it can minimize the generation of flake at the time of preparing the scrubber and economically further maximize the cleaning effect of the scrubber.

The toilet scrubber 100 includes a functional non-woven fabric layer 20 laminated on one side of the foregoing non-woven cleaning fabric layer 10. The toilet scrubber of the present invention can effectively remove germs and bad smells, protect the toilet surface from contaminants, and suppress the propagation of germs on the toilet surface, by including the functional non-woven fabric layer 20.

The functional non-woven fabric layer 20 includes a second non-woven fabric and a functional composition formed on a surface of the second non-woven fabric and/or inside the second non-woven fabric.

The second non-woven fabric includes a second polyester-based staple fiber, a second polyamide-based staple fiber, or a mixture thereof. Specifically, in the second non-woven fabric, the second polyester-based staple fiber(s) and/or second polyamide-based staple fiber(s) are both physically interlaced with and bonded to each other by various non-woven fabric preparing methods known in the art, like the first non-woven fabric. The toilet scrubber of the present invention has improved durability, resulting in extending the lifespan thereof, by including the second non-woven fabric.

The second polyester-based staple fiber is a synthetic fiber obtained by spinning a polymer containing an ester (—COO—) bond on a main chain and then slitting it into a predetermined length, like the first polyester-based staple fiber. Examples of the second polyester-based staple fiber are the same as those described in the first polyester-based staple fiber. However, in the present invention, the first polyester-based staple fiber and the second polyester-based staple fiber may be identical to or different from each other.

The fineness of the second polyester-based staple fiber is not particularly limited. However, when the fineness of the second polyester-based staple fiber is 20 to 80 denier and desirably 40 to 60 denier, like the fineness of the first polyester-based staple fiber. It can increase volume and improve touch of the final toilet scrubber and result in a reduction in the preparation cost.

The second polyamide-based staple fiber is a synthetic fiber obtained by spinning a polymer containing an amide (—CONH—) bond on a main chain and then slitting it into a predetermined length, like the first polyamide-based staple fiber. Examples of the second polyamide-based staple fiber are the same as those described in the first polyamide-based staple fiber. However, in the present invention, the first polyamide-based staple fiber and the second polyamide-based staple fiber may be identical to or different from each other.

The fineness of the second polyamide-based staple fiber is not particularly limited. However, when the fineness of the second polyamide-based staple fiber is about 20 to 80 denier and desirably about 40 to 60 denier, like the fineness of the first polyamide-based staple fiber, it can further volume feeling and touch feeling of the final toilet scrubber and result in a reduction in the preparation cost.

The functional non-woven fabric layer 20 of the present invention includes a functional composition. The functional composition coats a surface of the second non-woven fabric, or coats or fills an inside of the second non-woven fabric. The functional composition may be eluted at the time of using the toilet scrubber to thereby effectively remove germs and bad smells, and the eluted functional composition may form a protecting film on the toilet surface to thereby protect the toilet surface from contaminants and suppress the propagation of germs on the toilet surface.

The functional composition may include a functional polymer and one or more surfactant. Herein, the functional polymer is selected from the group consisting of a hydrophobic polymer, an acrylic acid polymer, a fluororesin, and a mixture thereof. The surfactant is a nonionic surfactant, an anionic surfactant, or a mixture thereof. In addition to these components, the functional composition may further include (a) a cationic surfactant, a germicide, or a mixture thereof; (b) a pigment, a dye, or a mixture thereof; (c) a perfume; and (d) a solvent.

The functional composition includes a functional polymer selected from the group consisting of a hydrophobic polymer, an acrylic acid polymer, a fluororesin, and a mixture thereof. When the functional composition includes the hydrophobic polymer, the functional composition eluted from the toilet scrubber may form a protecting film on the toilet surface and fewer contaminants may be attached on the toilet surface due to the formed protecting film. Meanwhile, when the functional composition includes the acrylic acid polymer, the property of the toilet surface is changed from hydrophobicity into hydrophilicity, so that the contaminants attached on the toilet surface are detached and thus easily removed. Meanwhile, when the functional composition includes the fluororesin, the contaminants can be prevented from being attached on the toilet surface due to the fluororesin, like the hydrophobic polymer.

Examples of the hydrophobic polymer are a siloxane-based polymer and the like. The siloxane-based polymer is not particularly limited as long as it contains a main chain in which silicon atoms and oxygen atoms are alternately bonded. Examples thereof are polysiloxane, polyalkylsiloxane, and polyarylsiloxane, and specifically, polyethylsiloxane, polymethylsiloxane, polyphenylsiloxane, and the like, but are not limited thereto.

The acrylic acid polymer includes an acrylic acid homopolymer consisting of only acrylic acid monomers, a cross-linked acrylic acid polymer consisting of acrylic acid monomers and a cross-linking agent, and the like, but is not limited thereto. Examples of the cross-linking agent are trimethylolpropane diallyl ether, trimethylolpropane triallyl ether, diallyl pentaerythritol ether, triallyl pentaerythritol ether, tetraallyl pentaerythritol ether, diallyl sucrose ether, triallyl sucrose ether, tetraallyl sucrose ether, and the like, but are not limited thereto.

In addition, the fluororesin usable herein is not particularly limited as long as it contains fluorine in the molecule thereof. Examples thereof are polytetrafluoroethylene (PTFE), polychlorotrifluoroethylene (PCTFE), polyvinylidene fluoride (PVDF), and the like, but are not limited thereto.

The amount of the functional polymer is not particularly limited. However, when the amount of the functional polymer is about 0.5 to 5 wt %, it can economically further improve anti-contaminating efficiency thereof and can be homogeneously mixed with other components.

According to one embodiment, the functional composition may be used in combination with a nonionic surfactant and/or anionic surfactant; and a cationic surfactant and/or germicide. By including the nonionic surfactant and/or anionic surfactant and the cationic surfactant and/or germicide, the functional composition can further improve cleaning, anti-contaminating, and germicidal functions, as compared with the cases where they are used alone. The nonionic surfactant and the anionic surfactant exhibit cleaning and anti-contaminating efficiencies, and the cationic surfactant and the germicide exhibit anti-biotic and anti-contaminating efficiencies.

Non-limited examples of the nonionic surfactant are ethylene diamine, diethylene glycol, dodecyl phenol, nonyl phenol, tetradecyl alcohol, N-octadecyl diethanolamide, N-dodecyl monoethanolamide, polyoxyethylene sorbitan monooleate, polyoxyethylene sorbitan monolaurate, and the like.

Non-limited examples of the anionic surfactant are sodium decylbenzene sulfonate, sodium dodecylbenzene sulfonate, ammonium methyl dodecylbenzene sulfonate, ammonium dodecylbenzene sulfonate, sodium octadecylbenzene sulfonate, sodium nonylbenzene sulfonate, sodium dodecylnaphthalene sulfonate, sodium heptadecylbenzene sulfonate, potassium eicososyl naphthalene sulfonate, ethylamine undecylnaphthalene sulfonate, sodium docosylnaphthalene sulfonate, sodium octadecyl sulfate, sodium hexadecyl sulfate, sodium dodecyl sulfate, sodium nonyl sulfate, ammonium decyl sulfate, potassium tetradecyl sulfate, diethanolamino octyl sulfate, triethanolamine octadecyl sulfate, ammonium nonyl sulfate, ammonium nonylphenoxyl tetraethylenoxy sulfate, sodium dodecylphenoxy triethyleneoxy sulfate, ethanolamine decylphenoxy tetraethyleneoxy sulfate, potassium octylphenoxy triethyleneoxy sulfate, and the like, but are not limited thereto. They may be used alone or in a mixture of two or more thereof.

The amount of the nonionic surfactant, anionic surfactant, or mixture thereof is not particularly limited, but when the amount thereof is 10 to 35 wt % based on the total weight of the functional composition, the coating efficiency thereof can be improved and the cleaning effect thereof can be economically further improved.

Non-limited examples of the cationic surfactant used herein are benzalkonium chloride, ethyl-dimethylstearyl ammonium chloride, benzyl-dimethyl-stearyl ammonium chloride, benzyldimethyl-stearyl ammonium chloride, trimethyl stearyl ammonium chloride, trimethylcetyl ammonium bromide, dimethylethyl dilaurylammonium chloride, dimethyl-propyl-myristyl ammonium chloride, and the like.

Non-limited examples of the germicide are zinc pyrithione, sodium pyrithione, dipyrithione, ketaconazole, salicylic acid, chlorhexidine gluconate, 2,4,4-trichloro-2-hydroxy diphenyl ether, and the like, which may be used alone or in a mixture of two or more thereof.

The amount of the cationic surfactant, germicide, or mixture thereof is not particularly limited, but when the amount thereof is 0.5 to 1 wt % based on the total weight of the functional composition, the anti-contaminating and germicidal effects can be economically further improved.

The pigment and/or dye used herein are/is not particularly limited as long as it can be easily eluted together with other components at the time of being contacted with water. Non-limited examples of the pigment or dye are Nylosan Blue, Hostafine Blue, and AquaLor Blue, water-soluble dyes such as Direct Blue 76, Direct Blue 86, Direct Blue 108, Direct Blue 199, Direct Blue 236, Acid Blue 9, Acid Blue 78, Acid Blue 82, and Acid Blue 234, and the like. Due to the inclusion of the pigment and/or dye, the color of the toilet scrubber becomes lighter as the toilet scrubber is more often used, so that the replacement time of the toilet scrubber can be anticipated.

The amount of the pigment, dye, or mixture thereof is not particularly limited, but may be controlled to be 0.05 to 10 wt % based on the total weight of the functional composition depending on the coloring degree of the functional non-woven fabric layer.

The perfume used herein may remove bad smells by covering bad smell substances. Therefore, the present invention can further exhibit a deodorizing effect and further exhibit an aromatic effect by including the perfume.

Examples of the perfume are general aromatic perfumes or natural aroma oils on the market. Specifically, examples thereof are citrus-based perfumes such as lemon, orange, and citrus, peppermint oil, citronella oil, rose oil, lavender oil, jasmine oil, lemon oil, orange oil, sandalwood, frankincense, German chamomile oil, and the like, but are not limited thereto.

The perfume may be capsulated by a polymer capsule. When the perfume is capsulated by the polymer capsule, the loss of perfume due to the pressure or temperature for preparing the scrubber or the formation of the functional composition can be prevented, and thus the unit cost of the perfume can be reduced and the deodorizing and aromatic effects can be improved. Further, the perfume itself can be stably treated and stored at the time of preparing the scrubber.

The amount of the perfume is not particularly limited, but when the amount thereof is about 0.1-3 wt % based on the total weight of the functional composition, the deodorizing effect can be enhanced without deteriorating the anti-biotic effect, and the aroma effect can be better exhibited.

The solvent used herein is not particularly limited as long as it can easily dissolve the functional polymer; the nonionic surfactant and/or anionic surfactant; the cationic surfactant and/or germicide; the pigment and/or dye; and the perfume. Examples of the solvent are water and the like.

The amount of the solvent is not particularly limited, and may be a remainder that controls the total weight of the functional composition to be 100 wt %.

The viscosity of the functional composition is not particularly limited. However, when the viscosity of the functional composition is 200 to 600 cps, it can easily coat a surface of the second non-woven fabric and fill the inside of the second non-woven fabric by a roll coating method or the like.

In addition, the coating amount (use amount) of the functional composition is not particularly limited, but when the coating amount thereof is 20 to 40 parts by weight based on 100 parts by weight of the second non-woven fabric, it can minimize the generation of flake at the time of preparing the scrubber and economically maximize the cleaning, anti-biotic, and deodorizing effects of the scrubber.

Meanwhile, the toilet scrubber may be prepared by various methods, and thus the preparation of the toilet scrubber is not limited to the following method.

According to one embodiment, the toilet scrubber may be prepared by including the steps of: forming a first non-woven fabric by using a first polyester-based staple fiber, a first polyamide-based staple fiber, or a mixture thereof; coating a cleaning composition on the first non-woven fabric to form a non-woven cleaning fabric layer; forming a second non-woven fabric by using a second polyester-based staple fiber, a second polyamide-based staple fiber, or a mixture thereof; coating a functional composition on the second non-woven fabric to form a functional non-woven fabric layer; laminating the non-woven cleaning fabric layer on the functional non-woven fabric layer to form a laminate sheet; and cutting the laminate sheet.

Hereinafter, the method for preparing the toilet scrubber is described as follows, but is not limited to the one exemplified below.

First, a first non-woven fabric including a first polyester-based staple fiber, a first polyamide-based staple fiber, or a mixture thereof is formed (hereinafter, ‘step S100’).

In step S100, bonding between the first polyester-based staple fibers, between the first polyamide-based staple fibers, or between the first polyester-based staple fiber and the first polyamide-based staple fiber, of a first web, may be conducted by a non-woven fabric preparing method known in the art. For example, the first polyester-based staple fibers are physically interlaced with each other to form the first web, and these first polyester-based staple fibers in the first web are bonded to each other by an adhesive, thermal bonding, or the like, to thereby form the first non-woven fabric.

According to one embodiment, step S100 includes the steps of: forming the first web consisting of the first polyester-based staple fiber and/or first polyamide-based staple fiber; and bonding the fibers of the first web to each other by the non-woven fabric preparing method known in the art.

The forming method of the first web is not particularly limited as long as it may be known in the art. For example, the first web may be formed by physically separating the first polyester-based staple fibers on a conveyor by using an opening machine, and then uniformly or randomly arranging the first polyester-based staple fibers by using a carding machine.

The fibers of the formed first web may be bonded to each other by thermal, physical or chemical methods, such as binding the fibers to each other by an adhesive or melting the fibers and bonding them to each other.

Then, a non-woven cleaning fabric layer 10 is formed by forming a cleaning composition on the first non-woven fabric formed in step S100 (hereinafter, ‘step S200’).

In step S200, the cleaning composition is formed on a surface of the first non-woven fabric or inside the first non-woven fabric. Specifically, the cleaning composition may coat the surface of the first non-woven fabric, and/or may fill an inside of the first non-woven fabric, that is, pores of the first non-woven fabric.

According to one embodiment, step S200 includes the steps of coating the cleaning composition on the surface and/or the inside of the first non-woven; and heating the coated cleaning composition to form the non-woven cleaning layer.

The coating method of the cleaning composition is not particularly limited, and non-limited examples thereof are roll coating, dip coating, spray coating, gravure coating, flexo printing, slot die coating, curtain coating, slide coating, and the like.

The heating temperature may be 160 to 200° C. and desirably 170 to 190° C. and the heating time may be 3 to 7 minutes, but they are not limited thereto. According to one embodiment, the non-woven cleaning fabric layer may be formed by coating the cleaning composition on the first non-woven fabric by a roll coating method and then drying it in an oven at 180° C. for 3 to 7 minutes.

Then, a second non-woven fabric including a second polyester-based staple fiber, a second polyamide-based staple fiber, or a mixture thereof is formed (hereinafter, ‘step S300’).

In step S300, the second non-woven fabric is formed by carrying out the same process as step S100 as described above. Here, the forming method and bonding method of the second web are the same as those of step S100 as described above. However, when the second polyester-based staple fiber is used at the time of forming the second non-woven fabric, the second polyester-based staple fiber may be identical to or different from the first polyester-based staple fiber used in step S100. Meanwhile, when the second polyamide-based staple fiber is used at the time of forming the second non-woven fabric, the second polyimide-based staple fiber may be identical to or different from the second polyamide-based staple fiber used in step S100.

Hereinafter, a functional non-woven fabric layer 20 is formed by forming a functional composition on the second non-woven fabric formed in step S300 (hereinafter, ‘step S400’).

In step S400, the functional composition is formed on a surface of the second non-woven fabric and/or inside the second non-woven fabric. Specifically, the functional composition may be coated on the surface of the second non-woven fabric, and/or may fill the inside of the second non-woven fabric, that is, pores of the second non-woven fabric.

According to one embodiment, step S400 includes the steps of coating the functional composition on the surface and/or the inside of the second non-woven fabric; and heating the coated functional composition to form the functional non-woven fabric.

The coating method of the functional composition is not particularly limited, and non-limited examples thereof are roll coating, dip coating, spray coating, gravure coating, flexo printing, slot die coating, curtain coating, slide coating, and the like.

The heating temperature may be 160 to 200° C. and desirably 170 to 190° C. and the heating time may be 3 to 7 minutes, but they are not limited thereto. According to one embodiment, the functional non-woven fabric layer may be formed by coating the functional composition on the second non-woven fabric by a roll coating method and then drying it in an oven at 180° C. for 3 to 7 minutes.

Then, a laminate sheet is formed by laminating the non-woven cleaning fabric layer formed in step S200 on the functional non-woven fabric layer formed in step S400 (hereinafter, ‘step S500’).

The method of laminating the non-woven cleaning fabric layer on the functional non-woven fabric layer is not particularly limited as long as it may be known in the art. For example, the methods is bonding the non-woven cleaning fabric layer and the functional non-woven fabric layer by using an adhesive; heating and pressing the non-woven cleaning fabric layer and the functional non-woven fabric layer by allowing the laminated sheet to penetrate between a pair of preheated rollers, and the like.

Then, the laminate sheet is cut into predetermined shape and size (hereinafter, ‘step S600’).

The shape of the laminate sheet is not particularly limited, and for example, may be a polygonal shape, a circular shape, or the like. When both sides of the scrubber have a shape of S, such a scrubber is favorable since it can easily clean even an inside of the toilet.

Meanwhile, a toilet cleaner has the foregoing toilet scrubber. As shown in FIG. 3, the toilet cleaner may include the toilet scrubber 100 and a handle 200 connected to one side of the toilet scrubber 100. Here, the handle 200 can be easily connected to and separated from the toilet scrubber 100, and thus the toilet scrubber can be continuously replaced.

Hereinafter, the present invention will be described with reference to examples and comparative examples in detail. However, the following examples are intended to explain the present invention, and so the present invention is not limited to these examples.

Example 1 <Step 1> Preparation of Non-Woven Cleaning Fabric Sheet

A cleaning composition was prepared by mixing 25.3 wt % of sodium dodecylbenzene sulfonate, 16.2 wt % of triethanolamine, 0.13 wt % of AquaLor Blue 283L, and the remainder water. Then, the cleaning composition was coated on the non-woven fabric (polyethylene terephthalate staple fiber (thickness: 50 denier)) to prepare a non-woven cleaning fabric sheet.

<Step 2> Preparation of Functional Non-Woven Fabric Sheet

A functional composition was obtained by mixing 5 wt % of polymethylsiloxane, 14 wt % of Ethoxyalted Alchol (Miwon Commercial Company, LAE7), 1 wt % of benzalkonium chloride (Miwon Commercial Company, Miconuim), 0.5 wt % of AquaLor Blue (Wooshinpigment Company), 0.5 wt % of Lemon Citrus Fragrance (Hanbit Flvor & Fragrance, Company). Then, the functional composition was coated on the non-woven fabric (polyethylene terephthalate staple fiber (thickness: 50 denier)) to prepare the functional non-woven fabric sheet.

<Step 3> Preparation of Toilet Scrubber

A toilet scrubber was prepared by laminating the non-woven cleaning sheet prepared in <step 1> of Example 1 on one surface of the functional non-woven fabric sheet prepared in <step 2> of Example 1, and then cutting the laminate into predetermined shape and size.

Example 2

A toilet scrubber was prepared by the same method as Example 1, except that 5 wt % of 3M™ Protective Material PM-3630 from the 3M Company was used instead of 5 wt % of polymethylsiloxane used in <step 2> of Example 1.

Example 3

A toilet scrubber was prepared by the same method as Example 1, except that 5 wt % of Acusol 845 from the Dow Chemical Company was used instead of 5 wt % of polymethylsiloxane used in <step 2> of Example 1.

Comparative Example 1

Scotch-Brite™ Clean Stick also known as Scotch-Brite™ Disposable Toilet Bowl Scrubber from the 3M Company was used for Comparative Example 1.

Experimental Example 1 Evaluation on Cleaning Efficiency

The cleaning efficiency of the toilet scrubber according to the present invention was evaluated as follows.

Waste engine oil, steak sauce, and rice paste were respectively coated on surfaces of tiles (10 cm×10 cm), followed by heating at 145 for 1 hour. After that, the toilet scrubbers of Examples 1 to 3 and Comparative Example 1 were fitted with a push-pull tester, which was then allowed to reciprocate on the surfaces of the respective contaminated tiles 20 times. After that, the whiteness and contaminant removal for the respective tiles were measured, and then shown in FIGS. 4 to 6.

As the experimental results, the toilet scrubbers of Examples 1 to 3 (A, B, and c in FIGS. 4 to 6, respectively) had a superior effect in removal of contaminants as compared with the toilet scrubber of Comparative Example 1 (D in FIGS. 4 and 6).

Experimental Example 2 Evaluation on Anti-Contaminating Efficiency

The anti-contaminating efficiency of the toilet scrubber according to the present invention was evaluated as follows.

Glass surfaces were respectively cleaned by the toilet scrubbers of Examples 1 to 3 and Comparative Example 1, and then frictional forces of the respective glass surfaces were measured by using a frictional force tester. After that, the glass surfaces respectively cleaned by the toilet scrubbers were coated with steak sauce, and then the frictional force of the steak sauce layer formed on each of the glass surfaces was measured by using the frictional force tester. In addition, the frictional force of the glass surface was measured by using the frictional force tester. In addition, the glass surface not cleaned by the toilet scrubber was coated with the steak sauce, and then the frictional force of the steak sauce layer was measured by the frictional force tester. The contamination rate was calculated by Mathematical Equation 1.

$\begin{matrix} {{{contamination}\mspace{14mu} {rate}} = \frac{\left( {f_{4} - f_{3}} \right)}{\left( {f_{2} - f_{1}} \right)}} & \left\lbrack {{Mathematical}\mspace{14mu} {Equation}\mspace{14mu} 1} \right\rbrack \end{matrix}$

(Wherein Mathematical Equation 1,

f₁ is surface frictional force of glass,

f₂ is surface frictional force of steak sauce layer formed on glass surface,

f₃ is surface frictional force of glass cleaned by toilet scrubber, and

f₄ is surface frictional force of steak sauce layer formed on glass surface cleaned by toilet scrubber.)

The calculation results of contamination rate were shown in FIG. 7. FIG. 7 showed that the lower the value, the more superior the anti-contaminating efficiency.

As the experimental results, the toilet scrubbers of Examples 1 to 3 (A to C in FIG. 7) had lower contamination rates than the toilet scrubber of Comparative Example 1 (D in FIG. 7). Specifically, the toilet scrubber of Example 1 (A in FIG. 7) had a contamination rate of 75%, which showed superior anti-contaminating efficiency as compared with the Comparative Example 1 having a contamination rate of approximately 89%.

As described above, it may be confirmed that the toilet scrubber according to the present invention had superior anti-contaminating efficiency as compared with the toilet scrubber of the prior art.

Experimental Example 3 Anti-Biotic Efficiency Test

The germicidal efficiency of the toilet scrubber according to the present invention was evaluated as follows.

Test on Staphylococcus ATCC 6538

Staphylococcus ATCC 6538 was inoculated on tile surfaces respectively cleaned by the toilet scrubbers of Examples 1 to 3, and then the staphylococcus count at the initial stage of inoculation was measured. After 5 minutes, the staphylococci on the respective tile surfaces were counted. Here, a tile cleaned by the toilet scrubber of Comparative Example 1 was used for a comparative sample. The count results were shown in Table 1 and FIG. 8 below.

TABLE 1 Staphylococcus Staphylococcus Staphylococcus Count at Initial Count 5 minutes Reduction Stage of Inoculation after Inoculation Rate (%) Comparative 3.6 × 10⁵ CFU/mL 1.3 × 10² CFU/mL 99.9 Example 1 Example 1  0.0 × 10 CFU/mL >99.9 Example 2 3.5 × 10³ CFU/mL 99.9 Example 3  0.0 × 10 CFU/mL >99.9

As the test results, 99.9% of staphylococci were removed by the respective toilet scrubbers of Examples 1 to 3, like the toilet scrubber of Comparative Example 1. Especially, in the case of the tiles respectively cleaned by the toilet scrubbers of Examples 1 to 3, 99.9% or more of staphylococci were remarkably removed.

Test on Escherichia Coli ATCC 25922

Escherichia Coli ATCC 25922 was inoculated on tile surfaces respectively cleaned by the toilet scrubbers of Examples 1 to 3, and then the E. coli count at the initial stage of inoculation was measured. After 5 minutes, E. coli on the respective tile surfaces were counted. Here, a tile cleaned by the toilet scrubber of Comparative Example 1 was used for a comparative sample. The count results were shown in Table 2 and FIG. 9 below.

TABLE 2 E. Coli E. Coli E. Coli Count at Initial Count 5 Minutes Reduction Stage of Inoculation After Inoculation Rate (%) Comparative 4.9 × 10⁵ CFU/mL 4.1 × 10⁵ CFU/mL 15.6 Example 1 Example 1 1.7 × 10² CFU/mL 99.9 Example 2 2.0 × 10² CFU/mL 99.9 Example 3 3.7 × 10¹ CFU/mL 99.9

As the test results, 99.9% or more of E. coli were remarkably removed when the toilet scrubbers of Examples 1 to 3 were used. On the contrary, it can be found that E. coli existed as the initial stage of inoculation when the toilet scrubber of Comparative Example 1 was used.

The toilet scrubber of the present invention can provide superior anti-biotic, anti-contaminating, and deodorizing effects as well as a superior cleaning effect on the toilet surface, by including the non-woven cleaning fabric layer including the cleaning composition and the functional non-woven fabric layer including the functional composition.

Although a preferred embodiment of the present invention has been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.

BRIEF DESCRIPTION OF THE INDICATIONS

-   -   1, 100: toilet scrubber,     -   2, 200: handle,     -   10: non-woven cleaning fabric layer,     -   20: functional non-woven fabric layer 

1. A toilet scrubber comprising: a non-woven cleaning fabric layer comprising a cleaning composition, and a functional non-woven fabric layer comprising a functional composition.
 2. The toilet scrubber according to claim 1, wherein the cleaning composition comprises an anionic surfactant; an ethanolamine-based compound; a pigment, a dye, or a mixture thereof; and a solvent.
 3. The toilet scrubber according to claim 1, wherein the functional composition comprises a functional polymer and one or more surfactant.
 4. The toilet scrubber according to claim 3, wherein the functional polymer is selected from the group consisting of a hydrophobic polymer, an acrylic acid polymer, a fluororesin, and a mixture thereof, and the surfactant is a nonionic surfactant, an anionic surfactant, or a mixture thereof.
 5. The toilet scrubber according to claim 4, which further comprises: (a) a cationic surfactant, a germicide, or a mixture thereof, (b) a pigment, a dye, or a mixture thereof, (c) a perfume, and (d) a solvent.
 6. The toilet scrubber according to claim 1, wherein the non-woven cleaning fabric layer comprises a first polyester-based staple fiber, a first polyamide-based staple fiber, or a mixture thereof, and the functional non-woven fabric layer comprises a second polyester-based staple fiber, a second polyamide-based staple fiber, or a mixture thereof, wherein the first polyester-based staple fiber and the second polyester-based staple fiber are independently selected from the group consisting of polyethylene terephthalate staple fiber, polyethylene naphthalate staple fiber, polybutylene terephthalate staple fiber, poly(1,4-cyclohexylenedimethylene terephthalate) staple fiber, polyester ether staple fiber, polyetheretherketone staple fiber, and a mixture thereof, and the first polyamide-based staple fiber and the second polyamide-based staple fiber are independently selected from the group consisting of nylon 6, nylon 66, nylon 11, nylon 610, nylon 612, nylon 4, aromatic nylon and aramid.
 7. A toilet cleaner comprising: the toilet scrubber of claim 1, and a handle connected to one side of the toilet scrubber.
 8. A method of preparing a toilet scrubber comprising the steps of: forming a first non-woven fabric by using a first polyester-based staple fiber, a first polyamide-based staple fiber, or a mixture thereof; coating a cleaning composition on the first non-woven fabric to form a non-woven cleaning fabric layer; forming a second non-woven fabric by using a second polyester-based staple fiber, a second polyamide-based staple fiber, or a mixture thereof; coating a functional composition on the second non-woven fabric to form a functional non-woven fabric layer; laminating the non-woven cleaning fabric layer on the functional non-woven fabric layer to form a laminate sheet; and cutting the laminate sheet. 